Process of manufacturing reflector incandescent lamps.



No. 870,233. PATENTED NOV. 5, 1907. H. GILMORE.

PROCESS OF MANUFACTURING REFLECTOR INOANDESGENT LAMPS.

APPLIOATION FILED AUG.16, 1905. RENEWED MAY 29, 1907.

2 SHEETS-SHEET 1.

No. 870,233- PATENTED NOV. 5, 1907.

H. GILMORE.

PROCESS OF MANUFACTURING REFLECTOR INUANDESOENT LAMPS.

APPLICATION FILED AUG.16,1905. RENEWED MAY 29,1907.

2 SHEETSSHEET 2.

UNITED STATES PATENT OFFICE.

HOWARD GILMORE, 0F BROOKLINE, MASSACHUSETTS.

PROCESS OF MANUFACTURING REFLECTOR INCANDESGENT LA MPS.

Specification of Letters Patent.

Patented Nov. 5, 1907.

Application filed August 16.1905- Serial No. 274.386. Renewed May 29. 1907- Serial No. 376.417.

scription, in connection with the accompanying draw-- ing, is a spccificationj-like letters on the drawings representing like parts.

This invention relates to a process for manufacturing a certain class of incandescent lamps that are provided with a metallic reflector surrounding the filament stem and located inside the glass bulb of the lamp. Hitherto these lamps have usually been manufactured by cutting open the end of the glass bulb, inserting the metallic reflector which is in the shape of a large concave disk, together with .the other parts contained in the bulb, and then sealing up the partsof the severed glass bulb. This process of sealing is objectionable in several ways. In the first place, even when done most carefully it leaves the glass bulb wrinkled. This wrinkling of the bulb makes the lamp unsightly, and also causes the production of shadows. In the second place the process is an expensive one, and requires very expert workmen to obtain even moderately satisfactory results.

The object of the present invention is to do away' with the objections attendant upon the old process of manufacturing these lamps, and is first, to improve the finished appearance of the lamp, second, to improve the light giving qualities, and third to cheapen the cost of manufacture.

In the process of this invention the reflector and other parts are inserted in the bulb without cutting the bulb open, and this is done by inserting them through the neck of the-bulb, which comes from the glass blower in open form. The process also involves certain methods of handling the parts while in the bulb to get them into proper position, together with other steps, all of which are more fully set forth in the accompanying description, and the invention itself is more particularly defined in the appended claims. By this process I am enabled to produce a reflector incandescent lamp with a smoothunbroken bulb just as it comesfrom the glass blower, the neck through which the parts are inserted being concealed in the usual manner by the base of the lamp.

The drawings represent a completed lamp, together with various views showing the lamp in different stages of manufacture in the carrying out of my process.

In the drawings, Figure 1 is a view in central vertical cross-section of the completed lamp manufactured 'by the use of the process of this invention; Fig. 2 represents the bulb from which the lamp is formed as it comes from the glass blower, with the tube at the tip attached, and the neck cut off and'rounded; Fig. 3 infull lines represents a plan view of the reflector, and in dotted lines of the reflector curled up; Fig. 4 is a view illustrating the step of inserting the reflector into the bulb; Fig. 5 is a view illustrating the step of restoring the reflector to shape; Fig. 6 is a view showing the parts in position for the inserting of the filament stem; Fig. 7 is a view showing the step of the insertion of the filament stem; Fig. 8 is a view showing the filament stem inserted; Fig. 9 is a view showing the step of bringing the reflector and filament stem into position; Fig. 10 shows the reflector and filament stem in position with the weight falling from the bulb; Fig. 11 shows the filament stem expanded ready for sealing to the edge of the bulb; Fig. 12 shows the construction of the neck of the bulb after the stem is sealed thereto.

In the manufacture of these reflector incandescent electric lamps the glass bulb A is formed in the usual manner. The bulb at first is blown into a mold until it takes a form substantially as shown in Fig. 2 without the tube a and with the neck B somewhat elongated.

The tube a is then fused to the tip of the bulb and a hole formed therein to communicate with the interior of the bulb, and at the same time the neck is cut off and rounded to the form shown in Fig. 2. This leaves the bulb with the short open neck B, with the long tube a by which it can. be handled, and through which when the lamp is completed the air can be exhausted, and then-sealed by the fusing off of the tube a. These steps are all familiar and well-known in the manufacture of incandescent lamps, and form no part of the present invention. They are preliminary to the process of the present invention.

The reflector shown at C in Fig. 3 is a concave disk of some bright or highly polished metal, such for exple as aluminium. To secure its function as a reflector it is necessary that it should cover. a considerable portion of the interior surface of the bulb, and as I have before explained it has hitherto been placed within the bulb by cutting off the lower end of the bulb to form a sufficient opening to allow for its insertion, after which the parts of the bulb are sealed together, leaving the glass wrinkled, producing an unsightly appearance and causing the producing of shadows. This process requires great skill on the part of the workman, and is expensive. In the present invention I introduce the reflector and the other parts of the device usually attached to the filament stem through the open neck B of the bulb, thus preserving the bulb intact.

' The first step in the process and one of the important steps-is bending or curling the reflector into-such form as to allow of its insertion through the neck of the bulb B. The simplest and best way of accomplishing this ate p is to bend the reflector or curl it into substantially cylindrical form of suflicient diameter to allow of its introduction into the bulb. When aluminium reflectors, which are soft, are used this may be easily done by bending it around the finger.

The second and essential step of the process is of inserting the bent or curled reflector into the bulb, which is accomplished by dropping it in as shown in Fig. 4. This step leaves the reflector in curled form inside of the bulb.

The third step, which so far as I know is essential, is the restoring of the reflector to substantially normal shape. In the case of soft metal, such as aluminium, the reflector after being dropped into the bulb will retain its curled or bent form and must forcibly be bent into shape. With some springy metals and when the reflector is comparatively small as compared with the diameter of the neck, it is possible that the reflector might take a substantially normal shape without active manipulation; but in the practical application of the process I have found a mechanical manipulation of the reflector to restore it to substantially normal shape an essential step of the process. Any method of doing this is Within the scope of my invention. done by the'finger of the operator alone. 1, however, prefer to use mechanical devices such as illustrated in Fig. 5. I provide first a holder consisting of a suitable handle I), to which is attached a bent arm d. The arm (1 takes preferably substantially the form of the outline of the neck and a portion of the bulb, and presents at its lower end a deflected portion d substantially at right-angles to the portion corresponding to the neck of the bulb. It will thus be seen that when the holder D is inserted in the bulb it will take the position indicated in Fig. 5 and present the portion d at right-angles to and below the neck B of the bulb. The holder D is provided on the deflected portion d with a seat 11 having a projecting center' (1 to enter the central opening 0 of the reflector, and an eccentric projecting pin (l to enter a correspondingly eccentrically placed hole 0 in. the reflector. The second device employed is a presser E, and a narrow flat blade 6 pivoted to the lower end thereof and provided with a projecting center pin e. In using these devices the holder D and the presser E are inserted in the bulb, and the parts are then manipulated until the bent or curled reflector is seated over the center of and the pin d". The center 6 of the presser E is then placed in the central opening d of the seat (1- of the holder D, and by gradually turning and at the same time slightly reciprocating the presser E the reflector will gradually and speedily be brought to substantially its normal shape. This operation While somewhat complex in its description is very simple in its actual performance, and it is found that with instruments such as described the reflector is very readily restored to substantially its normal shape. I say substantially its normal shape, because, as will be seen subsequently the reflector is pulled into place against the inner wall of the bulb which serves to give it and hold it in the desired concave form, so that it is not absolutcly necessary that the step'of the process now being described should bring the reflector into exact form.

The next step of the process is the inserting of the It can be s'roass 'filai'rient stem with the filament in thebulb, and the bringing of the reflector and filament stem into position for securing in place. This step may be per formed in different ways, any of which I consider to be within the scope of my invention. The step in fact involves several manipulations of the parts, and while the ultimate result may be accomplished in different ways, I consider the manipulations herein described for performing this step as impprtant and valuable features of the invention. Y

At the conclusion of the preceding step the holder D and the presser E, or whatever instrumentalities have been used are removed and the-bulb remains at one end and provided at that end with a cushioning ring f whichslides easily on the interior of the glass bulb. I then manipulate the .parts by joggling them andby using the finger or some simple instrument,

such for example as illustrated at O in Fig. 7, until the reflector is seated upon the weight, as shown in Fig. 6, the hole 0 being alined with the chamber f. I then take the filament stem G with its attached filament G and insert it through the neck of the bulb into the alined holes 0 and f. This is best done by handling the filament stem with the forked tool 0, as shown in Fig. 7. When the parts are in place they will be in the position illustrated in Fig. 8. In the construction shown a spiral spring H is illustrated surrounding the filament stem. This is not essential but is desirable in the 'final construction of the device, because whenthe parts are secured in position this spring acting against the head of the filament stem and the reflector will hold the latter without rattling, snugly and firmly, against the bulb. The spring has a do pending end h which passes throughthe hole 1; in the reflector previously described and thus prevents the reflector from rotating.

While I consider the use of the weight as above described a preferable and most satisfactory step in the process, still the use of the weight is not absolutely essential, because the filament stem can be placed not thereby made this order essential, and that it is within my invention as described and claimed to insert the weight before the reflector.

After the parts are brought into position as shown in Fig. 8 if the weight is used, or in a substantially similar way 'if the weight be omitted, I then bring them into the position in which they are secured in place bysimply rotating the bulb carefully so as not to disturb materially the vertical position of the stem,

reflector and weight. This is easily accomplished,

and in Fig. 9 the parts are shown as going through this'operation, the weight maintaining the inclosed parts vertical and sliding around the side wall of the bulb as the latter is rotated. As the bulb is brought into vertical position with the neck downward the weight will fall out through the neck and the parts will assume the position shown in Fig. 10, which is the position in which they are to be secured in place.

While I refer to the foregoing step as one in which the bulb is rotated, and while in practice I find the actual rotation of the bulb to be preferable because it allows the weight to fall by gravity from the neck and leave the reflector and filament stem in position for securing in place, still I do not intend to be limited in any wayto this exact manipulation of the bulb, for it is evident that all that is essential is that the biilb on the one hand and the filament stem and reflector on the other shall be rotated the one with respect to the other.

When the parts are in the position illustrated in Fig. 9 the filament may be conveniently adjusted or bent into proper form by the insertion of suitable instruments through the neck of the bulb.

The final step of thc-process'is the securing of the assembled parts in position. This may be accom plished in any way, and be within the scope of my invention. In carrying out this step I preferably draw the stein G down through the opening of the bulb to compress the spring H, and then heat the end of the stem and expand or flare it out'as indicated at g, in Fig. 11, until it is of suflicient size to overlap the edge of the bulb. I next by the use of suitable means not necessary to describe and in a manner readily unstood by any one familiar with the art, fuse the flaring end 9 of the stem to the end 6 of the neck B of the bulb, when the parts will take the form shown in Fig. 12, presenting a closed air-tight end to the bulb.

The foregoing constitutes the steps involved in practicing the present invention. The finishing of the lamp is performed in the usual and well-known manner and need not be described in detail, since itjorms no part of the present invention. The air is exhausted through the tube a, and thereupon the tip of the bulb is sealed and the tube melted 0E. The bulb in then inserted in a suitable socket M, as indicated in Fig. 1, onewire of the filament being attached to the wall of the socket, and the other wire to-a central contact m.

Having described my invention, what I claim as new and desire to secure by Letters Patent, is:

1. In the process of manufacturing a reflector incandescent lamp, wherein the reflector is curled and inserted through the neck of thevbulb, the following steps, viz. first, inserting the filament stem and connected parts through the neck of the bulb; second, bringing the reflector and filament stem into axial alinement with the neck and thereafterchanging the relative position and securing ln place.

2. In the process ofmanufacturing a reflector incandescent lam'p, wherein the reflector is curled and inserted through the neck of the bulb, the following steps, viz:- flrst, restoring the reflector to substantially normal shape by mechanical manipulations;.second, inserting the illsment stem and connectcdparts through the neck of the bulb: third, bringing the reflector and filament stem into axial alinement with the neck and thereafter changing the relative position and securing in place.

3. In the process of manufacturing a reflector incandescent lamp, wherein the reflector is curled and inserted through the neck of the bulb. the following steps, via, first, inserting the filament stem with its connected parts through the neck and into the aperture of the reflector; second. rotating the bulb until the filament stem drops into the neck, leaving the reflector and stem substantially in position for securing in place.

4. In the process of manufacturing a reflector incandescent lamp, wherein the reflector is curled and inserted tlu-ough the neck or the bulb, the following steps, viz., iirst, restoring the reflector to substantially normal position; second. inserting the filament stem with its connectcd parts through the neck and into the aperture of the reflector; third, rotating the bulb until the filament stem drops into the neck, leaving the reflector and stem substantially in position for securing in place.

In the process of manufacturing a reflector incan descent lamp, wherein the reflector is curled and inserted through the neck of the bulb, the following steps, viz., first, inserting a chambered weight into the bulb through the neck; second, positioning the reflector on the weight; third. inserting the filament stem with its connected parts through the neck and into the alined apertures of the reflector and weight; fourth, rotating the bulb until the weight falls out of the neck, leaving the reflector and stem substantially in position for securing in place.

.6. In the process of manufacturing a reflector incan-.

descent lamp, wherein the reflector is curledand inserted through ,the neck of thebulbpthe following steps, viz., first, restoring the reflcctorto substantially normal position; second, inserting a chambered weight into the-bulb through'the neck; third, positioning; the reflector on the weight: fourth. inserting the filament stem with its connected parts through the neck and into the alined apertures of the reflector and weight; fifth, rotating the bull; 'until the weightfalls out of the neck, leaving the reflector and stem substantially in position for securing in place.

7. In the process of manufacturing va reflector lncan descent lamp, wherein the reflector is'curled and inserted through the neck-of the bulb, the following steps, vlz., first, restoring the reflector to substantially normal position; second, inserting a chambered weight into the bulb through the'- neck; third, positioning the reflector on the weight; fourth, inserting the filament stem with its conne'cted parts through the neck and into the alined apertures of the reflector and weight; fifth, rotating the bulb until the weight falls out of the neck, leaving the reflector and'stern,substantially in position for securing, in place; sixth, sealing the stem to the neckof the bulb.

8. In the process of manufacturing a reflector incandescentlamp, wherein the reflector is curled and inserted through the neck of the bulb, the following steps, viz..- flrst, restoring the reflector to substantially normal position; second, inserting a chambered weight into the bulb through the neck; .third, positioning the reflector on the welght; fourth lnserting the filament stem with its connected parts through the neck and'into the alined apertures of the reflector and weight; fifth, rotating the bulb until the weight falls out of the neck, leaving the reflector and stem substantially in position for securing in place;

HOWARD GILMORE.

Witnesses Ns'rnav Emu,

Manna PAB'IELOW- 

